Occupational Hazard Identification and Workplace Safety Control Practices in a Sugar Manufacturing Facility: A Descriptive Observational Study in Lampung, Indonesia

Abstract

Sugar manufacturing facilities involve complex industrial operations that expose workers to various occupational hazards, including machinery-related risks, noise, vibration, heat, airborne dust, and ergonomic stressors. Identifying these hazards and assessing existing workplace safety controls are important components of occupational injury prevention and occupational health management. This study aimed to identify potential workplace hazards and describe occupational safety control practices at a sugar manufacturing facility in Lampung, Indonesia. A descriptive observational study was conducted through a workplace walkthrough survey at PT X Lampung on May 7, 2026. Data collection involved direct workplace observations, an occupational health and safety (OHS) checklist, brief interviews with company personnel, and a review of available workplace safety information. The assessment focused on physical, chemical, mechanical, ergonomic, and organizational hazards, as well as existing preventive controls, personal protective equipment (PPE), emergency preparedness, and occupational health surveillance. Findings were evaluated descriptively to identify potential hazards and areas requiring additional preventive attention. The assessment identified several potential occupational hazards across production activities, including machinery noise in the milling area, vibration near heavy equipment, thermal exposure in evaporation and cooking areas, airborne dust in packaging operations, and chemical handling in laboratory and cleaning areas. Ergonomic concerns included awkward working postures, repetitive movements, and manual handling of heavy loads, particularly in packaging and warehouse activities. The facility reported established OHS management practices, including written safety policies, hazard identification procedures, PPE provision, workplace safety signage, fire protection equipment, evacuation arrangements, first-aid facilities, and occupational medical examinations. A fitness-for-duty classification system and a seven-step occupational disease diagnostic framework were also described. However, the completeness and effectiveness of these measures could not be independently established through the available observational information. Ergonomic risk evaluation was identified as an area requiring further attention, particularly for repetitive tasks and manual material handling. This study identified multiple potential occupational hazards and documented existing workplace safety control practices in a sugar manufacturing facility. Although general OHS infrastructure and preventive procedures were reported, further assessment is needed to verify control implementation and evaluate ergonomic risks systematically. Strengthening task-specific hazard assessment, ergonomic improvements, mechanical handling support, and periodic safety evaluations may contribute to more comprehensive occupational risk management. Because occupational exposure measurements, accident records, and intervention outcomes were not available, the effectiveness of existing controls in reducing workplace accidents could not be determined.